Baldor GLC60 - Manuals

1‐2 Product Safety Information MN2408 This symbol is shown throughout the manual to indicate a connection to ground reference point. Symbols Indicates a potentially hazardous situation which, if not avoided, could result in injury or death. Indicates a potentially hazardous situation which, if not a...

Product Safety Information 1‐3 MN2408 Operation Warning Statements Continued WARNING: Never connect or disconnect loads during operation. Always connect load circuits before starting the engine and use external branch disconnects etc. to switch loads On/Off. WARNING: Be sure that you understand how ...

1‐4 Product Safety Information MN2408 Warning Statements Continued InstallationWARNING: Installation and servicing of batteries is to be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel awayfrom batteries. WARNING: Disconnect t...

1‐6 Product Safety Information MN2408 Warning Statements Continued MaintenanceWARNING: Before cleaning, inspecting, repairing or performing any maintenance to the generator set, always be sure the engine has stopped and that all rotating parts have also stopped. Afterstopping, certain components are...

Section 2General Information General Information 2‐1 MN2408 Thank you for purchasing your Baldor Generator Set. This manual contains information you need to safely andefficiently install and operate your generator set. During the preparation of this manual every effort was made toensure the accuracy...

General Information 2‐3 MN2408 Important Be sure you are completely familiar with all Safety Instructions detailed in Section 1 of thismanual. Do not proceed if you are unsure of any detail. Contact your Baldor Distributor, they areexperienced and are happy to assist you and to answer your questions...

2‐4 General Information MN2408 Room Location Often a separate building located on the site away from the main building is the most simple and cost effective. Major considerations when housing the genset in a separate building are: S Maintain the building at a satisfactory temperature year round (to ...

General Information 2‐5 MN2408 Foundation DesignWARNING: An open bottom stationary engine generator set must be installed over noncombustible materials and shall be located such that it prevents combustible materials from accumulatingunder the generator set. Foundation Checklist A. Evaluate if a sep...

2‐6 General Information MN2408 S Steel spring isolators are a very effective and commonly used. Steel spring isolatorsare typically 95-98% efficient (reduces the transmitted vibration 95-98%) while a padtype can be 75-88% efficient. Spring isolators also level the genset sub-base in theevent the fou...

General Information 2‐7 MN2408 Designing An Isolated Foundation If the genset cannot be mounted directly on a floor slab, or if it is desirable to isolate it from thefloor slab, then a separate foundation slab must be designed.A massive concrete foundation is not required. Outside dimensions of the ...

2‐8 General Information MN2408 Table 2‐1 Approximate Load Bearing Capacities of Various Soil Types Soil Type Safe Bearing Capacity lb per ft 2 kilo Pascals Hard Rock - Granite etc. 50,000 - 200,000 2,395 - 9,576 Medium Rock - Shale etc. 20,000 - 30,000 958 - 1,436 Hardpan 16,000 - 20,000 766 - 958 S...

General Information 2‐9 MN2408 Exhaust System Exhaust Checklist A. Exhaust outlets are not located upwind or near any building air intakes.B. Flexible piping section is used at engine exhaust outlet.C. Exhaust piping material is adequate for expected service.D. Exhaust piping sizing is adequate to p...

2‐10 General Information MN2408 Figure 2‐6 Exhaust System Calculations Exhaust PipingCaution: The weight of the exhaust system must never be imposed on the turbo-charger outlet.Damage to the turbo-charger and other components may result. An exhaust system must withstand the vibration and thermal exp...

General Information 2‐11 MN2408 Transfer Switch Transfer Switch Checklist A. Locate transfer switch in a clean, dry place, near the emergency load. B. Provide a circuit breaker between the genset and the transfer switch. C. Put a flexible connection between the conduit and genset.D. Observe applicab...

2‐12 General Information MN2408 6. Conduit, wire, circuit protective device sizes, insulation etc. must conform to applicablelocal and national codes and regulations. 7. Be certain to seal around conduits that penetrate the walls of the genset room toreduce the amount of noise that is transmitted to...

General Information 2‐13 MN2408 Battery Charger An engine mounted alternator charges the batteries during engine operation. Standby gensetsshould include a solid state battery charger that is connected to utility power so the battery ischarged continuously while the genset is not running. The batter...

Section 3Receiving & Installation Receiving & Installation 3‐1 MN2408 Receiving & Inspection When you receive your generator, there are several things you should do immediately. 1. Observe the condition of the shipping container and report any damage immediately tothe commercial carrier ...

3‐2 Receiving & Installation MN2408 WARNING: An open bottom stationary engine generator set must be installed over noncombustible materials and shall be located such that it prevents combustible materials from accumulatingunder the generator set. Several other factors should be carefully evaluat...

Receiving & Installation 3‐3 MN2408 Secure the Generator Six (eight for the GLC125) mounting bolts in the base frame secure the generator to the shippingpallet. Remove these bolts, lift the generator and remove the shipping pallet. Secure thegenerator to the concrete pad using 3 / 8 ″ anchor har...

3‐4 Receiving & Installation MN2408 Hot Exhaust GassesWARNING: Exhaust fumes/gases are extremely dangerous and can cause severe illness or death. Never breath exhaust fumes produced by a running engine. Only run the engine outdoors whereventilation is plentiful. Exhaust gases contain carbon mono...

Receiving & Installation 3‐5 MN2408 8. As much of the exhaust piping as possible should be located near the power ventilationexhaust. This will reduce the radiant exhaust heat inside the building. 9. Keep all fuel and its associated piping away from all components of the engine exhaustsystem. 10...

3‐6 Receiving & Installation MN2408 Installation The generator is completely assembled, tested and adjusted at the factory before it is shipped toyou. The procedures presented in this manual are suggestions and it is the responsibility of theOwner/Operator to arrange for these procedures to be p...

Receiving & Installation 3‐7 MN2408 Example: Determining Pipe Size for Natural Gas A generator has a 16Hp engine 60 feet from the supply. Determine the supply pipe size for Natural Gas fuel.16 x 10,000 = 160,000 BTU's / per hour for proper operation. 160, 000 1, 096 + 146cubicfeetperhour. From T...

3‐8 Receiving & Installation MN2408 Example: Determining Pipe Size for LPV A generator has a 16Hp engine 60 feet from the supply. Determine the supply pipe size for Natural Gas fuel.16 x 10,000 = 160,000 BTU's / per hour for proper operation. 160, 000 2, 516 + 63.5cubicfeetperhour. From Table 3‐...

Receiving & Installation 3‐9 MN2408 Electrical Connections Class 1 wiring methods must be used for field wiring connections to terminals of a class 2 circuit. It is the responsibility of the owner/operator to arrange for these procedures to beperformed by a licensed electrical contractor and ens...

3‐10 Receiving & Installation MN2408 Transfer Switch Considerations The following are general considerations for the safe use of a transfer switch: 1. The transfer switch should be located inside the building near the main breaker box orthe disconnect box. 2. The transfer switch must be kept awa...

Receiving & Installation 3‐11 MN2408 Figure 3‐5 Single Phase Connections From Alternator(Factory Wired) AC Power Connections Neutral Connections Ground Connections LOAD NEUTRAL GROUND Customer Connections Bond Jumper L1 L2 Note: Remove the Bondingjumper to meet localcodes if required. Figure 3‐6...

3‐12 Receiving & Installation MN2408 Battery Charger Considerations 1. Mount the battery charger on the generator or as close to the generator as possible. 2. If you mount the battery charger inside the building, mount it near the main breaker boxor disconnect box. 3. If you mount the battery ch...

Receiving & Installation 3‐13 MN2408 Battery Connections The generator may be shipped with no battery installed. Procedure: The correct type battery must be installed in the battery compartment provided, see Table 3‐7.Installation and servicing of batteries is to be performed or supervised by pe...

3‐14 Receiving & Installation MN2408 Post Installation Checks When the initial installation is complete, these checks must be performed before starting theengine. These checks are not required before each start, only after the initial installation. 1. Generators that have been in transit or stor...

Receiving & Installation 3‐15 MN2408 Post Installation Checks Continued 22. With the engine running, several checks must be made: a. Verify there are no fuel leaks. If a fuel leak is detected, stop the engineimmediately (move the Master Control Switch to the “Stop” position) and repair the leak ...

Section 4Operation Operation 4‐1 MN2408 Digital Engine Controller Description EM0046A21 (MRS17) Figure 4‐8 Operator Control Panel Stop Manual Run Display Menu Group LED Indicators Operating Modes and Horn & Fault Reset Note: The operator control panel is equyipped with a heater element that allo...

4‐2 Operation MN2408 Digital Engine Controller Description EM0046A21 (MRS17) Continued Operating Mode Press Mode or to scroll though the list of operating modes: Off, Manual and Automatic. The control mode is shown in the highlighted area at the top of the display, Figure 4‐9.When the desired Contro...

4‐4 Operation MN2408 Alarms Following alarms are available: Sensor fail (FLS) see Table 4‐10 Sensor fail is detected when measured value is 6% out of selected sensor characteristic. Sensor fail is indicated by ##### symbol instead measured value. Warning (WRN) see Table 4‐10 When warning comes up, o...

Operation 4‐5 MN2408 Inputs and Outputs Any Binary input or output can be configured to any controller terminal Inputs are BI1 - BI6,Outputs are BO1 - BO6) or changed to different function by LiteEdit software. There is fixed 1 sec delay when any binary input is configured as protection. Table 4‐11 ...

4‐6 Operation MN2408 Analog Inputs Three analog inputs for resistive sensor 0 to 2400 ohms measuring are available on IL controller.Use LiteEdit software to modify configuration.The Analog inputs values assignment (AI1 = Oil press, AI2 = Water temp, AI3 = Fuel level) is fix.It is possible to configu...

Operation 4‐7 MN2408 Table 4‐15 Engine Setpoints Start RPM “Firing” speed when iL controller stops cranking (starter goes OFF).Step: 1% of nominal RPM; Range: 5 - 50 % Starting POil When reached controller stops cranking (starter goes OFF).Step: 0,1 psi; Range: -100 - 10000Note: There are three cond...

4‐8 Operation MN2408 Table 4‐15 Engine Setpoints Continued Cooling time Runtime of the unloaded gen-set to cool the engine before stop.Step: 1s; Range: 0 - 3600 s AfterCoolTime Runtime of engine after cooling pump. Binary output Cooling pump isclosed when the engine starts and opens AfterCool time d...

Operation 4‐9 MN2408 Table 4‐17 Generator Protect Setpoints Overload Threshold for generator overload (in % of Nominal power)Step: 1% of Nominal power; Range: 0 - 200% Overload Wrn Threshold for generator overload warning (in % of Nominal power)Step: 1% of Nominal power; Range: 0 - 200% Overload del...

4‐12 Operation MN2408 Digital Engine Controller Description EM0046A21 (MRS17) Continued Figure 4‐12 Controller Connection Diagram LOAD E M E RGE NCY S T O P R E M O TE S STAR T/STO P DI ESE L /GASENGIN E START ER BATTERY - + FU EL SO LEN O ID GENERATOR G BINARYOUTPUTS STARTER L1 L2 L3 N PRESTART PE ...

Operation 4‐13 MN2408 Operator Control Panel (MICROPROCESSOR Engine Controller Only) The Operator Control Panel is shown in Figure 4‐13. WARNING: Never connect this generator to any buildings electrical system unless a licensed electrician has installed an approved transfer switch. The National Elec...

4‐14 Operation MN2408 Operator Control Panel Continued Auto Switch - When pushed, initiates automatic operation of the engine (generator set). Starting and stopping of the engine is controlled by aremote contact (transfer switch). When the remote start signal is removed the engine will continue to r...

Operation 4‐17 MN2408 No Load Test To allow a timed No Load Test of the engine/generator set while using the AMF controlapplication, a digital input contact from an external timer must be programmed for NO LOAD TestThe sequence of operation for a No Load Test condition is as follows: 1. With the uti...

4‐18 Operation MN2408 Figure 4‐15 Engine Controller Inputs & Outputs

Operation 4‐19 MN2408 Analog Faults Eight analog fault inputs are user programmable for 12 fault conditions. Each analog fault input requires a specific analogsignal type. FaultName FaultAction InputsSignal Low Engine Temperature Alarm Engine Temperature High Engine Temperature #1 Alarm Engine Tempe...

4‐20 Operation MN2408 Output Contacts All output contacts are non-powered (i.e. dry contacts) and are rated 10A/240VAC, 8A/28VDCresistive (3A inductive, 0.4pf). Output contacts are not fused therefore external overcurrentprotection (maximum 10A) is required for all control circuits using these conta...

Operation 4‐21 MN2408 Display Modes The controller is in the display mode at all times except when in the programming mode. Thedisplay screens and menus may be selected by pressing the Enter or Exit keys to accessOperating Status Display, Fault Display, Timer Countdown, Generator AC Metering orProgr...

4‐22 Operation MN2408 Timer Countdown Timer countdown menus are automatically displayed when a specific time delay function occurs during a control sequence. When a time delay begins, the LCD display will show the timedelay function name (i.e. Engine Start Delay) and the current time remaining in th...

4‐24 Operation MN2408 Engine Parameter Display Two engine operating parameter screens are provided. Battery Voltage/Engine Speed(Tachometer) BATTERYSPEED 27.0 Vdc1800 rpm Battery Displays battery voltage in DC volts. The voltage is displayed with a resolution of 1/10 of a volt. Speed Displays engine...

Operation 4‐25 MN2408 Navigation Hints Programming parameters are displayed in the same order as the Programming Sheets (seeFigures 4‐17 to 4‐20). To skip over parameters that do not require changes, push and hold theENTER push-button until the desired parameter is displayed. The EXIT push-button ma...

4‐26 Operation MN2408 Main Menu Loop Continued Loss Of Speed Signal Select the desired action (i.e. alarm or shutdown) when a loss of speed signal is detected during operation. Note: A loss of speed signal must be detected for longer than 2 seconds to initiate the desired action. Common Fail For “No...

Operation 4‐27 MN2408 Digital Fault Menu Loop The controller's digital fault settings are described as follows: Caution: The Digital Fault Label selection must agree with the external control wiring prior toenergizing the controller. Failure to do so may cause severe equipment damage. Digital Fault ...

4‐28 Operation MN2408 Span Calibration Energize the generator supply voltage to the controller at nominal level. Note: It may be necessary to program theoptional under and over voltage shutdowns as alarms to ensure the generator will continue to operate during calibration.Caution must be taken to en...

Operation 4‐29 MN2408 Engine Temperature & Oil Pressure Calibration To accurately calibrate the controller's temperature sensor, an external temporary engine mountedtemperature gauge is required. The external temperature gauge should be connected as close as possibleto the temperature sender. To...

4‐30 Operation MN2408 Figure 4‐16 Configuration Data Sheet j j j j j j j j j

Operation 4‐31 MN2408 Figure 4‐17 Main Menu Loop Parameters Parameter Setting Range System Voltage (Line To Line) XXXXX VAC 120-15000V AC System Frequency 50Hz/60Hz Toggle Between 50/60 Hz System Phases 1 Phase/3 Phase Toggle Between 1 & 3 Phase Neutral Connected Toggle Between Yes/No Voltage Se...

Operation 4‐33 MN2408 Figure 4‐21 Engine Control Connections 1 2 3 4 5 6 7 8 9 10 11 12 17 16 15 14 13 38 37 GRD CR MP2 MP1 19 18 24 23 B - B + + - CRANK RUN 25 26 27 28 29 30 31 32 33 34 24 35 36 22 21 20 PROGRAMMABLECONTACT #4 PROGRAMMABLECONTACT #3 PROGRAMMABLECONTACT #2 PROGRAMMABLECONTACT #1 CO...

Section 5Troubleshooting and Maintenance Troubleshooting and Maintenance 5‐1 MN2408 Maintenance This manual contains only very minimal engine maintenance instructions. Refer to the enginemanufacturer's owner's manual for specific engine maintenance instructions for your generatorset. Any maintenance...

5‐2 Troubleshooting and Maintenance MN2408 Problems and Solutions Some of the more common problems are listed in Table 5‐1. This information is intended to be acheck or verification that simple causes can be located and fixed. It is not an exhaustive “how to”for all types of problems. Procedures tha...

Troubleshooting and Maintenance 5‐3 MN2408 Table 5‐2 Troubleshooting Guide (Digital Controller Only) Problem Possible Cause Remedy Controller does not power up even withcorrect DC power applied Wiring Mistake Overload Condition Check that there are no wiring errors/short circuits connected to thecon...

5‐4 Troubleshooting and Maintenance MN2408 Note: See Engine Controller manual for additional information. Table 5‐3 Troubleshooting Guide (Analog Controller Only) Problem Possible Cause Remedy Controller cannot be “Reset” Engine not stoppedController not in OFF mode Verify the engine is at a complet...

Appendix AOptions & Accessories Options & Accessories A‐1 MN2408 Battery Charger BTCGR6 Battery Charger - 12 Volt / 6 Amp Float. Includes 6 ft power cord with grounding plugfor AC input power and 4 ft power cord with ring terminals for DC output. UL Listed. BTCGR10A Battery Charger - 12 Volt...

A‐2 Series GLC MN2408 Battery Heaters Battery Heater (BTHTR81) - 120 Volt / 80 Watt. Includes 6 ft power cord. Installation Considerations: Shore power must be available (120VAC or 240VAC) to power the battery heater and othercomponents that may be installed). Shore power outlets or wiring must be l...

Options & Accessories A‐3 MN2408 Engine Block Heater Installation Considerations: Shore power must be available (120VAC or 240VAC) to power the block heater and othercomponents that may be installed). Shore power outlets or wiring must be located close to blockheater. Figure A‐3 Catalog # G10A B...

A‐4 Series GLC MN2408 Silencers Refer to enclosure procedure to install silencer when enclosure is present.Industrial Silencer for Open Skid Mount Units - Provides silenced exhaust for up to 11 dBAsound attenuation. Kit includes engine adapters, flex pipe, clamps, silencer, and rain cap.Critical Sil...

Options & Accessories A‐5 MN2408 Fuel Strainers & Fuel Lines A fuel strainer and flexible fule line can be installed at the fuel pressure regulator to makeconnection to the fuel main shutoff valve easier. Either 1-1/4” or 2” fittings may be specified. Figure A‐5 Fuel Strainer and Flex Fuel L...

A‐6 Series GLC MN2408 E-Stop E-Stop Switch Kit - Mounts to Baldor supplied Enclosure to provide easy access to shut downengine with the press of a button. Connects to Remote Run Terminals on genset. Must beadapted for remote mounting when used with open skid mount units. Figure A‐6 1 3 Installation:...

Options & Accessories A‐7 MN2408 Remote Annuciators Remote Annunciator - For use with MEC2 Controller. Provides remote anunciation of faults andgenerator status. Up to 20 individual fault conditions are remotely monitored utilizing both visualLED lights & audible alarm annunciation. Lamp tes...

A‐8 Series GLC MN2408 Radiator Duct Flange Radiator Duct Flange for Open Skid Mount - Provides easy connection to air ducting to carryaway hot air from engine radiator. Duct flange mounts to front of engine radiator. Add 3” to length. Figure A‐9 Table A‐1 Mounting Dimensions Generator A B C GLC10-25...

Options & Accessories A‐9 MN2408 Enclosures Weather Resistant Enclosure - Heavy-duty 12 gauge hot rolled steel with welded corners andbaked powder coat finish. Fasteners are zinc chromate plated and the locking latches arechrome plated on the lift off access doors. Silencer is mounted on top of ...

Appendix BSeries GLC Information & Wiring Diagrams Series GLC B‐1 MN2408 GLC Circuit Breaker & Electrical Data Circuit Breaker Size Qty per Phase Min Wire Gauge OSH Plant Ampacity @125C 15 1 #16 1 - #8 EPDM PER PHASE 90 20 1 #16 1 - #8 EPDM PER PHASE 90 30 1 #14 1 - #8 EPDM PER PHASE 90 40 1...

B‐2 Series GLC MN2408 Figure B‐11 Customer Interface Connection Diagram MEC20 MEC2

Series GLC B‐3 MN2408 Figure B‐12 Customer Interface (w/o Breaker) Power Connection Diagram

B‐4 Series GLC MN2408 Figure B‐13 Single Phase - (w/o Breaker) Connection Diagram

Series GLC B‐5 MN2408 Figure B‐14 Single Phase - One Breaker Connection Diagram

B‐6 Series GLC MN2408 Figure B‐15 Single Phase - Two Breaker Connection Diagram

Series GLC B‐7 MN2408 Figure B‐16 Single Phase Connection Diagram (Wire 1/0 and Larger w/Breaker)

B‐8 Series GLC MN2408 Figure B‐17 Single Phase Connection Diagram (Wire 1/0 and Smaller w/Breaker)

Series GLC B‐9 MN2408 Figure B‐18 Single Phase Connection Diagram (Wire 1/0 and Smaller w/o Breaker)

B‐10 Series GLC MN2408 Figure B‐19 Single Phase Connection Diagram (Wire Larger than 1/0 w/o Breaker)

Series GLC B‐11 MN2408 Figure B‐20 Three Phase Connection Diagram

B‐12 Series GLC MN2408 Figure B‐21 Three Phase Connection Diagram with PMG

Series GLC B‐13 MN2408 Figure B‐22 Three Phase Connection Diagram (Wire 1/0 and larger)

B‐14 Series GLC MN2408 Figure B‐23 Three Phase Connection Diagram (Wire Larger than 1/0 w/Breaker)

Series GLC B‐15 MN2408 Figure B‐24 Three Phase Connection Diagram (Wire 1/0 and Smaller w/Breaker)

B‐16 Series GLC MN2408 Figure B‐25 Three Phase Connection Diagram (Wire Larger than 1/0 w/o Breaker)

Series GLC B‐17 MN2408 Figure B‐26 Three Phase Connection Diagram (Wire 1/0 and Smaller w/o Breaker)

B‐18 Series GLC MN2408 Figure B‐27 Control Box Connections with MEC20 Controller

Series GLC B‐19 MN2408 Figure B‐28 Control Box Connections with MEC20 Controller & Governor

B‐20 Series GLC MN2408 Figure B‐29 Control Box Connections with MEC2 Controller

Series GLC B‐21 MN2408 Figure B‐30 Engine Wiring, Woodward 4.3L GM

B‐22 Series GLC MN2408 Figure B‐31 Engine Wiring, Woodward 5.7L GM

Series GLC B‐23 MN2408 Figure B‐32 Engine Wiring, Woodward 8.1L GM

© Baldor Electric Company MN2408 All Rights Reserved. Printed in USA 2/08 WARNING: CALIFORNIA PROPOSITION 65 WARNING: Engine exhaust from this product contains chemicals knownto the state of California to cause cancer, birth defects andother reproductive harm. WARNING: CALIFORNIA PROPOSITION 65 WARN...